System and method for mounting a waterproofing system to shoring for an excavation wall

ABSTRACT

System and method for mounting a waterproofing system comprising a waterproof membrane to shoring for an excavation wall. The mounting system comprises an induction disc having a conductive element, a first disc surface coated with an adhesive, and a second disc surface opposite the first disc surface. A target patch is affixed to the first disc surface by induction welding. The target patch has an outer portion which extends beyond the periphery of the induction disc. The outer portion is affixed to the waterproof membrane. A first hydrophilic washer is secured between the waterproof membrane and the second disc surface of the induction disc. A second hydrophilic washer is secured between the target patch and a rigid washer. A mounting fastener, such as a lag bolt screw, screw, bolt or nail, extends through each of the components and is fastened to the shoring.

BACKGROUND

The field of the invention generally relates to below-grade waterproofing of building foundations and basements, which are typically installed prior to the construction, pouring or installation of the wall structure being waterproofed, and more particularly, to a system and method for mounting a waterproofing system to shoring for an excavation wall in which the mountings are sealed to prevent moisture from penetrating the waterproofing system at the mounting points.

It is known in structures having below-grade (i.e. sub-grade or underground) structures, such as large buildings with subterranean foundations, basements, mines and tunnels, to provide waterproofing to the underground structure to prevent groundwater from entering the structure. To this end, waterproofing systems have been developed, such as waterproof membranes lining the below-grade walls, and drainage systems to drain water away from the walls. The waterproof membranes may be affixed directly to the structure walls or to the excavation walls, or to other layers of material used in the waterproofing system such as permeable or non-permeable geotextiles, drain boards used to drain the water, and/or other structures. The waterproof membranes are typically mounted to the structure walls using bolts or screws, such as lag bolt screws, inserted through the waterproof membranes and screwed into the shoring or other walls structure, lining the excavation walls.

SUMMARY

In one embodiment, the present invention is directed to an innovative system for mounting a waterproofing system to the walls of a structure, such as a building, tunnel or mine, having at least a part of the wall below-grade, in which the mounting points are sealed to prevent moisture (e.g., water) from penetrating through the mounting points. For instance, in the case of mounting fasteners such as lag bolt screws, screws, bolts or nails, used to mount a waterproof membrane, the mounting fasteners and apertures through which the fasteners penetrate the membrane are sealed to prevent moisture from penetrating at the location of the mounting fastener.

When constructing a structure, such as a building, an excavation is constructed in the earth in which the walls (and commonly the foundation) of the structure (e.g., a building, parking structure, etc.) will be constructed. Commonly, the earthen excavation walls are lined by shoring, such as wood shoring, mounted to the excavation walls which supports the excavation walls and also provides a useful base structure for constructing the main structure. The walls of the main structure, such as the foundation walls, are then constructed within the shoring and excavation walls. The walls of the main structure can be constructed of any suitable materials, but is commonly constructed of steel-reinforced concrete. For example, a concrete wall can be constructed by constructing forms and steel-reinforcement bar within the shoring and excavation walls and pouring into the forms over the reinforcement bars to construct and install the walls.

In order to waterproof the walls of the main structure, a waterproofing system is installed, typically, prior to constructing the walls of the main structure within the shoring, such that that waterproofing system is located between the shoring and the walls of the main structure. In this way, the waterproofing system prevents water, such as ground water, from accessing and building up around the walls of the main structure.

Various waterproofing systems are available for installing within the shoring and excavation walls for waterproofing the walls of the structure. For example, a waterproofing system may comprise one or more waterproof membrane(s), geotextile mat(s) mounted to, and covering, the shoring walls, and a water drainage system such as drain boards, drains, discharge conduits and/or sump pumps to extract water out of the excavation which prevents water from accessing and building up around the below grade walls of the structure. Thus, the waterproof membrane(s) and/or geotextile mat(s) are located on the outside of the walls of the structure being waterproofed. Several examples of systems and methods waterproofing below grade walls and the components used therein are described in U.S. Pat. No. 9,068,319, the contents of which is hereby incorporated by reference as if fully set forth herein. The waterproof membrane has a first side which is facing the wall of the structure to be installed (i.e. the inside surface, wherein the inside indicates toward the inside of the wall of the structure), and a second side facing toward the excavation wall.

According to one embodiment, the present invention is directed to a system for mounting a waterproofing system comprising a waterproof membrane to the shoring of an excavation wall. The waterproof membrane is mounted to the shoring using a plurality of mounting units spaced apart about the waterproof membrane at respective mounting points at which an aperture through the waterproof membrane is provided.

Each of the individual mounting units will now be described. Each mounting unit comprises an induction disc having a conductive element, a first disc surface coated with an adhesive, and a second disc surface opposite the first disc surface. A target patch is affixed to the first disc surface of the induction disc. The target patch has a first patch surface affixed to the first disc surface of the induction disc by induction welding the target patch to the inductive disc, and a second patch surface opposite the first patch surface. The surface area of the target patch is larger than the surface area of the induction disc such that the target patch has an outer portion which extends beyond the periphery of the induction disc. The outer portion is affixed to the waterproof membrane by any suitable method, such as by hot air welding, adhesive, etc.

A first hydrophilic washer is secured under the induction disc between the waterproof membrane and the second disc surface of the induction disc. A second hydrophilic washer is secured between the second patch surface and a rigid washer. Finally, a mounting fastener, such as a lag bolt screw, screw, bolt or nail, extends through each of the rigid washer, the second hydrophilic washer, the target patch, the induction disc, the first hydrophilic washer and the waterproof membrane, and the mounting fastener is fastened into the shoring (e.g., by screwing the mounting fastener into the shoring).

Accordingly, the plurality of mounting units provide a strong structural mounting of the waterproof membrane to the shoring. In addition, each mounting unit seals the mounting fastener and the aperture through the waterproof membrane which prevents moisture from penetrating the waterproof membrane at each of the mounting points.

In another aspect of the system for mounting a waterproofing system to shoring, the rigid washer may be a metal washer. In addition, the target patch may be made of polyvinyl chloride (“PVC”). Moreover, the waterproofing system may further comprise a geotextile mat covering the shoring and disposed between the shoring and the waterproof membrane. In such embodiments, the mounting fastener also extends through the geotextile mat such that the mounting unit also mounts the geotextile mat to the shoring. Of course, any other suitable layers and/or components of the waterproofing system may also be mounted to the shoring using the mounting units by simply putting the mounting fasteners through each of the other layers and/or other components.

In another embodiment, the present invention is directed to a method for mounting a waterproofing system comprising a waterproof membrane to shoring within an excavation for a wall of a structure. In other words, the method is for using the mounting units described above for mounting a waterproofing system. The waterproof membrane (and any other layers or components) are positioned over the shoring at the location at which they are to be mounted to the shoring. The waterproof membrane may have pre-constructed apertures at each of the respective mounting points about the membrane, or the apertures may be provided during the mounting process (such as by inserting the mounting fastener through the waterproof membrane and/or any other layers). The method for installing each of the mounting units will now be described. The first hydrophilic washer is secured between the waterproof membrane and the induction disc (as described above) by placing the induction disc over the first hydrophilic washer and compressing the washer against the waterproof membrane. A target patch (as described above) is affixed to the induction disc by induction welding the first patch surface to the first disc surface. Again, the target patch has an outer portion which extends beyond the periphery of the induction disc. The target patch may be affixed to the induction disc before or after securing the first hydrophilic washer between the induction disc and the waterproof membrane.

A second hydrophilic washer is secured between the second patch surface and a rigid washer. The mounting fastener is inserted through each of the rigid washer, the second hydrophilic washer, the target patch, the induction disc, the first hydrophilic washer and the waterproof membrane. The mounting fastener is then screwed into the shoring. Then, the outer portion of the target patch is affixed to the waterproof membrane.

The method for mounting a waterproofing system to shoring may include any one or more of the additional aspects described above for the system, including the aspects described for each of the mounting units.

Thus, a method for mounting a waterproofing system is provided which securely fastens the waterproofing system to the shoring and also seals the mounting fastener and the aperture through the waterproof membrane to prevent moisture the mounting points.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a mounting system for mounting a waterproofing system to shoring, according to one embodiment of the present invention;

FIG. 2 is a cross-sectional view showing the installation of a waterproofing system comprising a geotextile mat and a waterproof membrane disposed over shoring within an excavation for a wall of a structure, according to one embodiment of the present invention;

FIG. 3 is a cross-sectional view showing certain components in place after the initial steps of a method are completed for using a mounting system to mount the waterproofing system of FIG. 2 to the shoring, according to one embodiment of the present invention;

FIG. 4 is a cross-sectional view showing additional components in place after additional steps of the method are completed for using a mounting system to mount the waterproofing system of FIG. 2 to the shoring, according to one embodiment of the present invention.

DETAILED DESCRIPTION

Referring to FIG. 1, one embodiment of a mounting system 10 for mounting a waterproofing system 12 according to the present invention is shown. The present invention does not require all of the structure and features of the mounting system 10, but may include only those suitable for the particular installation. Turning to FIG. 2, the waterproofing system 12 is configured for waterproofing a wall 14 of a structure which when installed is at least partially below-grade, i.e. below the surface of the surrounding earth 16. When constructing large buildings, tunnels, mines and other structures having below-grade walls, an excavation is dug creating excavation walls 16 (earthen walls) within which the structure walls 14 and slab/foundation (not shown) of the structure will be constructed. The shoring 18 is constructed around the perimeter of the excavation to support the excavation walls 14. The shoring 18 typically comprises a plurality of beams (typically wood beams) which may be supported by steel piles (not shown) driven into the earth.

Still referring to FIG. 2, the waterproofing system 12 is installed within the shoring 18 which lines the excavation walls 14. The waterproofing system 12 is typically installed prior to constructing the walls 14 and slab (not shown), although, it may be possible to install the waterproofing system 12 after the slab and walls 14 are constructed. The waterproofing system 12 and mounting system 10 will be described for installation prior to constructing the walls 14 and/or slab, with the understanding that it is also possible to install them after constructing the walls 14 and slab.

The waterproofing system 12 comprises a backing layer 20 which is placed over the inside surface of the shoring 18, and covers most, or substantially all, of the shoring 18. As used herein, the term “inside surface” refers to the surface facing toward the interior of the structure (i.e. facing toward the wall 14), and “outside surface” refers to the surface facing toward the exterior of the structure (i.e., facing toward the excavation wall 16). The backing layer 20 may be any suitable material, such as a geotextile, for example “HYDRO-ULTRAMAT SERIES™” geotextiles available from Hydro-Gard LLC, in Yorba Linda, Calif. The waterproofing system 12 may comprise additional components between the backing layer 20 and the shoring 18, such as a drain board, and/or other sheet layer(s) and components (not shown).

The waterproofing system 12 also comprises a waterproof membrane 22 positioned over the inside surface of backing layer 20. The waterproof membrane 22 covers most, or substantially all, of the backing layer 20, and in turn covers most, or substantially all, of the shoring 18 and excavation wall 16. The waterproof membrane 22 may be any suitable waterproofing sheet material, such as HYDRO-PRUFE™ 80 mil available from Hydro-Gard LLC, in Yorba Linda, Calif. Multiple sheets of waterproof membrane 22 may be utilized to cover the entire surface of the backing layer 20. The seam between different sheets may be bonded together with a water-tight seal by heat welding the seam (e.g. using a hot air welder), as is known in the art.

With the backing layer 20 and the waterproof membrane 22 in place over the shoring 18, the mounting system 10 is then installed to mount the backing layer 20 and waterproof membrane 22 to the shoring 18, i.e., the waterproofing system 12 is mounted to the shoring 18. The mounting system 10 comprises one or more mounting units 10 (one exemplary mounting unit is shown in the figures) spaced apart about the area of the backing layer 20 and waterproof membrane 22 at respective mounting points for each mounting unit 10. For example, the mounting units 10 can be spaced apart in any suitable pattern, such as a rectangular array. For instance, the mounting units 10 may be spaced about 14″-15″ apart from center to center in a rectangular array over the waterproof membrane 22, or other suitable spacing and configurations may be used.

The backing layer 20 and waterproof membrane 22 may be provided with respective apertures at each of the mounting points for installing the mounting units 10. The apertures may be formed before or after placing the backing layer 20 and waterproof membrane 22, or the apertures can even be pre-formed in the backing layer 20 and/or waterproof membrane 22 by the manufacturer. Alternatively, the apertures can be formed by inserting and/or screwing a mounting fastener, such as a lag bolt screw 24, through the backing layer 20 and waterproof membrane 22, as described herein.

Each of the mounting units 10 and a method for installing each of the mounting units 10 will now be described with reference to FIGS. 1-4. Referring first to FIG. 3, a first hydrophilic washer 26 is positioned at a mounting point on the waterproof membrane 22 and is secured between the waterproof membrane 22 and an induction disc 28 by placing the induction disc 28 over the first hydrophilic washer 26 and compressing the washer 26 against the waterproof membrane 22. The hydrophilic washer 26 is formed of a hydrophilic material, such as vulcanized, hydrophilic expansive rubber, for instance, the SWELLSEAL® joint hydrophilic rubber material available from De Neef Construction Chemicals, Houston, Tex. The hydrophilic washer 26 may be any suitable shape. For example, the hydrophilic washer 26 may be a circular disc with a circular aperture in the middle, or it can be square shaped with an aperture in the middle, etc. The induction disc 28 comprises a circular disc having a first disc surface (the inside surface) facing away from the hydrophilic washer 26 which is coated with an adhesive and a second disc surface (the outside surface) opposite the first disc surface which is facing the hydrophilic washer 26. The induction disc 28 also has a conductive element which can be heated by an induction welder in order to activate the adhesive to bond the first disc surface to another surface. The induction discs 28 may be approximately 3 inch diameter discs, or other suitable size. For example, the induction discs may be the PVC Plate product from Valro Manufacturing Limited, in Knutsford, Cheshire, England, for use with the CENTRIX™ induction welding system. The discs 28 are mounted to the inside surface of the backing layer 20 or waterproof membrane 22 such that the bonding surface is exposed.

Still referring to FIG. 3, a target patch 30 is affixed to the first disc surface of the induction disc 28 by induction welding. The target patch 30 has a first patch surface (the outside surface) facing the induction disc 28 and a second patch surface (the inside surface) opposite the first patch surface. The first patch surface of the target patch 30 is placed on the first disc surface of the induction disc 28, and an induction welder is then used to induction weld the first patch surface to the first disc surface which activates the adhesive forming a first induction weld 32, thereby affixing the target patch 30 to the induction disc 28. The target patch 30 also has an outer portion 31 which extends beyond the periphery of the induction disc 28 such that the outer portion 31 can be pressed into contact with the waterproof membrane 22 over the induction disc 28 and the first hydrophilic washer 26.

Turning now to FIG. 4, a second hydrophilic washer 34 is placed against the second patch surface and is secured between the second patch surface and a rigid washer 36. The second hydrophilic washer 34 may be the same or similar in material and shape as the first hydrophilic washer 26, or, depending on the size of the rigid washer 36, it may be smaller or larger in order to fit within the perimeter of the rigid washer 36. The rigid washer 36 may be a metal washer, such as stainless steel, aluminum, etc., and may be any suitable shape, such as a circular disc having a circular aperture in the middle.

The lag bolt screw 24 is then inserted through each of the rigid washer 36, the second hydrophilic washer 34, the target patch 30, the induction disc 28, the first hydrophilic washer 26, the waterproof membrane 22 and the backing layer 20. The lag bolt screw 24 may be any suitable mounting fastener, such as a screw, a lag bolt screw, a bolt, a nail, or other elongate fastener which can be fastened to the shoring 18. If the waterproof membrane 22 and/or the backing layer 20 have not already been provided with apertures through the layers, then the lag bolt screw 24 is inserted and/or screwed through the waterproof membrane 22 and/or backing layer 20 thereby puncturing the waterproof membrane 22 and/or backing layer 20 and forming aperture(s) through such layers. The lag bolt screw 24 is then screwed into the shoring 18 until the head of the lag bolt screw 24 bears against the rigid washer 36 and a desired bearing force on the mounting unit 10 is established.

Turning back to FIG. 1, the outer portion 31 of the target patch 30 is affixed to the waterproof membrane 22. The outer portion 31 is pressed against the waterproof membrane 22 and is bonded to the waterproof membrane 22 by any suitable means to form a bond 23. For example, the outer portion 31 may be hot air welded to the waterproof membrane 22 using a hot air welder. Alternatively, the outer portion 31 may be bonded to the waterproof membrane 22 using an adhesive. The bond 23 may form a waterproof seal between the target patch 30 and the waterproof membrane 22 such that moisture cannot pass from between the waterproof membrane 22 and the target patch 30 around the perimeter of the target patch 30.

Continuing to refer to FIG. 1, after the waterproof system 12 is installed, the structure wall 14 can then be formed adjacent the waterproof membrane 22 and the mounting unit 10. The lag bolt screw 24 may have a threaded head into which a threaded rod (not shown) can be attached and used to construct forms for pouring a concrete wall as the structure wall 14.

Although particular embodiments have been shown and described, it is to be understood that the above description is not intended to limit the scope of these embodiments. While embodiments and variations of the many aspects of the invention have been disclosed and described herein, such disclosure is provided for purposes of explanation and illustration only. Thus, various changes and modifications may be made without departing from the scope of the claims. For example, not all of the components described in the embodiments are necessary, and the invention may include any suitable combinations of the described components, and the general shapes and relative sizes of the components of the invention may be modified. Accordingly, embodiments are intended to exemplify alternatives, modifications, and equivalents that may fall within the scope of the claims. The invention, therefore, should not be limited, except to the following claims, and their equivalents. 

What is claimed is:
 1. A system for mounting a waterproofing system comprising a waterproof membrane to shoring within an excavation for a wall of a structure, comprising: an induction disc having a conductive element, a first disc surface coated with an adhesive, and a second disc surface opposite the first disc surface; a target patch having a first patch surface affixed to the first disc surface by an induction weld, and a second patch surface opposite the first patch surface, the target patch having an outer portion which extends beyond the periphery of the induction disc, wherein the outer portion is affixed to the waterproof membrane; a first hydrophilic washer secured between the waterproof membrane and the second disc surface; a second hydrophilic washer secured between the second patch surface and a rigid washer; and a mounting fastener extending through the rigid washer, the second hydrophilic washer, the target patch, the induction disc, the first hydrophilic washer and the waterproof membrane, and fastened to the shoring.
 2. The system of claim 1, wherein the rigid washer is a metal washer.
 3. The system of claim 1, wherein the outer portion of the target patch is affixed to the waterproof membrane by a hot air weld.
 4. The system of claim 1, wherein the target patch is made of polyvinyl chloride material.
 5. The system of claim 1, wherein the target patch is made of polyvinyl chloride material and the outer portion of the target patch is affixed to the waterproof membrane by a hot air weld.
 6. The system of claim 1, wherein the waterproofing system further comprises a geotextile mat disposed between the shoring and the waterproof membrane, and the mounting fastener extends through the geotextile mat.
 7. The system of claim 1, wherein the first hydrophilic washer and the second hydrophilic washer comprise vulcanized, hydrophilic rubber.
 8. A method for mounting a waterproofing system comprising a waterproof membrane to shoring within an excavation for a wall of a structure, comprising: securing a first hydrophilic washer between the waterproof membrane and an induction disc, the induction disc having a conductive element, a first disc surface coated with an adhesive, and a second disc surface opposite the first disc surface, the first hydrophilic washer secured between the waterproof membrane and the second disc surface; affixing a target patch to the induction disc, the target patch having a first patch surface and a second patch surface opposite the first surface, by induction welding the first patch surface to the first disc surface, the target patch having an outer portion which extends beyond the periphery of the induction disc; securing a second hydrophilic washer between the second patch surface and a rigid washer; inserting a mounting fastener through the rigid washer, the second hydrophilic washer, the target patch, the induction disc, the first hydrophilic washer and the waterproof membrane; fastening the mounting fastener into the shoring; and affixing the outer portion of the target patch to the waterproof membrane.
 9. The method of claim 8, wherein the rigid washer is a metal washer.
 10. The method of claim 8, wherein the outer portion of the target patch is affixed to the waterproof membrane by hot air welding.
 11. The method of claim 8, wherein the target patch is made of polyvinyl chloride material.
 12. The method of claim 8, wherein the target patch is made of polyvinyl chloride material and the outer portion of the target patch is affixed to the waterproof membrane by hot air welding.
 13. The method of claim 8, wherein the waterproofing system further comprises a geotextile mat disposed between the shoring and the waterproof membrane, and the mounting fastener extends through the geotextile mat.
 14. The method of claim 8, wherein the first hydrophilic washer and the second hydrophilic washer comprise vulcanized, hydrophilic rubber. 